Systems and methods form induction rotors by performing isostatic pressing (HIP) to weld clad to a shaft, which allows for scaling the manufacturing of solid steel rotors, as compared to conventional techniques. In examples, the rotors are designed for high-speed motors and may include recessed short circuit rings and/or end rings. An exemplary process molds an alloy powder into cladding such that heretofore unachievable rotor designs are achievable according to systems and methods described herein. In examples, a thin source-layer is introduced to welding zones, thereby enriching and strengthening the resulting joint at welding zones. The source-layer may be introduced by adding an intermediate layer comprising the source material between the materials being welded. The reduced alloy-depletion welding disclosed herein strengthens the welding area joints and provides for the manufacture of component designs, which were previously unachievable due to alloy-depletion weaknesses and environmental constraints.

A method of forming a projectile for use in a firearm ammunition cartridge, the method including mixing a first material and a second material having different densities to produce a core mixture, disposing the core mixture in a die, heating the core mixture to the melting point, removing the core mixture from the die, quenching the core mixture, and plating the core mixture with a jacket material.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

Molybdenum-containing alloys, and associated systems and methods, are generally described. In certain embodiments, secondary and/or tertiary elements can be included, along with molybdenum, to provide beneficial properties during the sintering of the molybdenum-containing alloy. The molybdenum-containing alloys are, according to certain embodiments, nanocrystalline. According to certain embodiments, the molybdenum-containing alloys have high relative densities. The molybdenum-containing alloys can be relatively stable, according to certain embodiments. Inventive methods for making molybdenum-containing alloys are also described herein.

In various embodiments, metallic alloy powders are formed at least in part by spray drying to form agglomerate particles and/or plasma densification to form composite particles.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

A friction stir processing (FSP) tool includes a working material. The working material has a matrix phase and a particulate phase. The matrix phase includes tungsten and an alloy material. The particulate phase is located within the matrix phase, and the particulate phase has an indentation hardness less than 45 GPa.

In various embodiments, metallic alloy powders are formed at least in part by spray drying to form agglomerate particles and/or plasma densification to form composite particles.

The present invention relates to the field of metal additive manufacturing, and disclosed thereby is a method for printing a structure of a combustion chamber liner by using GRCop-84 spherical powder. The method mainly comprises the following steps: (1) establishing a model; (2) configuring printing parameters; (3) performing laser printing; (4) performing annealing treatment; and (5) performing surface sandblasting. The present invention uses GRCop-84 spherical powder as the material of a combustion chamber liner model, and said material has excellent electrical conductivity, thermal expansion, strength, creep resistance, ductility, fatigue and like properties, and the comprehensive performance thereof is excellent, which significantly improves the performance of a rocket engine. In the GRCop-84 spherical powder material of the present invention, Cr and Nb form a Cr2Nb phase, and the volume fraction of a second phase is about 14%, same being evenly distributed in a copper matrix. Moreover, the second phase is still stable when 1600° C. is exceeded, which enables the material to maintain good service performance at high temperatures.

A method for the manufacture of a three-dimensional object using a refractory matrix material is provided. The method includes the additive manufacture of a green body from a powder-based refractory matrix material followed by densification via chemical vapor infiltration (CVI). The refractory matrix material can be a refractory ceramic (e.g., silicon carbide, zirconium carbide, or graphite) or a refractory metal (e.g., molybdenum or tungsten). In one embodiment, the matrix material is deposited according to a binder-jet printing process to produce a green body having a complex geometry. The CVI process increases its density, provides a hermetic seal, and yields an object with mechanical integrity. The residual binder content dissociates and is removed from the green body prior to the start of the CVI process as temperatures increase in the CVI reactor. The CVI process selective deposits a fully dense coating on all internal and external surfaces of the finished object.